Technical Information
DIJET CARBIDE TOOLSTechnical Information
®
Tech
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l Inf
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atio
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G-1
Technical Information
Terminology and Formulas (for milling)
Dc =Cuttingdiameterae =Cuttingwidth(step)ap =Depthofcutfn =Feedrateperrevolutionfz =FeedratepertoothDe =EffectivecuttingdiameterVc =CuttingspeedQ =MetalremovalrateI =MachinedlengthVf =Tablefeed(feedrate)Dap=MaxcuttingdiameteratspecificdepthZn =Totalnumberofedgesinthetool
mm.mm.mm.mm.mm.mm.
m/mm.cm3/min.
mm.mm/min.
mm.
Zc =Effectivenumberofteethhex =Maxchipthicknesshm =Averagechipthicknesskc1 =Specificcuttingforce(hex=1mm)Pc =Netcuttingpowerkr =MajorcuttingedgeangleVco =ConstantforcuttingspeedCvc =Correctionfactorforcuttingspeedn =Spindlespeednmt =Efficiencymc =Riseinspecificcutingforce(kc) asafunctionofchipthickness
mm.mm.
N/mm2.KW.deg.
rev/min.KW
General formulas
Spindlespeed
Feedpertooth
Removalrate
EffectivecuttingdiameterDe=2xapx(Dc-ap)=mm.
Netpower
Cuttingtime
n==rev/min.Vcx1000
πxDc
fz==mm.Vf
nxzn
Q==cm3.apxaexVf
1000
Tc==min.lVf
Pc==KWapxaexVfxkc60x106xnmt
Cuttingspeed
Tablefeed(feedspeed) Vf=fzxnxzn=mm/min.
Feedperrevolution fn==mm/rev.
Specificcuttingforce kc=kc1xhnm-mc=mm/min.
Averagechipthickness(side&facemilling)whenae/Dc≤0.1
Averagechipthicknesswhenae/Dc≥0.1
Vfn
Vc==m/min.πxDcxn1000
hm=fz=mm.aeDc
sinkrx180xaexfz
πxDcxarcsin()aeDc
hm==mm.
a pmax.
®
Technical Information
G-2
Technical Information
Down Milling:-sameworkpiecedirection,feedrateand rotationofmillingcutter.-chipcross-sectionstartonthestrongest point.
Generally down milling should be preferedif rigid machine is available.
Up Milling:-thefeedrateofworkpieceiscounter-clock- wisetothesenseofmillingcutterrotation.-chipcross-sectionstartsontheweakest point.
Up milling should be applied on instable millingmachine and workpiece materials withhigher hardness.
Up Cut and Down Cut
Tool with central work piece
Formulas:
We suggest to work likethis when possible orin any case work withtangential tool exit.Up cut and down cut ispossible with Ae Max.2/3 of tool diameter.
Suggested milling operation
Formulas:
Tool with outside center work piece
sin(kr)x180xaexfzπxdcxarcsin()ae
dc
hm=hmxπ xarcsin()ae
dcfz=sin(kr)x180xae
a e=2/3xdc
a e=2/3xdc
hm=sin(kr)x360xaexfz
πxdcx[arcsin+arcsin]()2xae2dc()2xae1
dc
hmxπxdcx[arcsin+arcsin]fz=sin(kr)x360xae
()2xae2dc()2xae1
dc
APPLICATIONSTurning
Troubleshooting
•insertgrade•speeds&feeds
•others
•Changetotoughergrade•IncreaseSFMifchippingisontrailingedge•DecreaseSFMifchippingisonleadingedge•Adjustchipload•Minimizetooloverhang•Checkforinsertmovement/checkclamp
•insertgrade•speeds&feeds
•Changetomorewear-resistantgrade•DecreaseSFM
•insertgrade•insertshape
•speeds&feeds•others
•Changetomorecraterwear-resistantgrade•Changebreaker•Usepositiverakeinsert•DecreaseSFM•Adjustchipload
•insertgrade•insertshape
•others
•Changetotoughergrade•Uselargernoseradiusifallowable•Increasehonesize•Adjustchipload
•insertgrade•insertshape•speeds&feeds
•others
•Changetotoughergrade•Adjusthonesize•IncreaseSFM•Adjustdepthofcutperpass•Increasecoolantconcentrationand/orflow
•insertgrade•speeds&feeds
•Changemoreheat-resistantgrade•DecreaseSFM
Chipping
Flank Wear
Crater Wear
Broken Nose
Built-up Edge
Deformation
PROBLEM CAUSE RECOMMENDED ACTION
®
Tech
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l Inf
orm
atio
n
G-3
Technical Information
®
Technical Information
G-4
Technical Information
APPLICATIONSMilling
Troubleshooting
•insertgrade•speeds&feeds
•Changetotoughergrade•Increasethecuttingspeed•Reducethefeed/tooth
•insertgrade•speeds&feeds
•Useamorewear-resistantgrade•Reducethecuttingspeed•Increasethefeed/tooth
•insertgrade•speeds&feeds
•Useamorecraterwear-resistantgrade•Reducethecuttingspeed•Reducethefeed/tooth
•insertgrade•speeds&feeds
•insertshape
•Useatoughergrade•Adjustthecuttingspeed•Adjustthefeed/tooth•Useathickerinsert
•insertgrade•speeds&feeds•insertshape•toolshape
•Useamorewear-resistantgrade•Increasethecuttingspeed•Useapolishedinsert•Useahigherrakecutter
•insertgrade
•toolshape
•Increasethecuttingspeed•Reducethefeed/tooth•Useahigherrakecutter
Chipping
Flank Wear
Crater Wear
Broken Nose
Poor Surface Finish
Burrs, Chipping, etc.
PROBLEM CAUSE RECOMMENDED ACTION
•speeds&feeds •Reducethecuttingspeed•Reducethefeed/tooth
Vibration
®
Tech
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l Inf
orm
atio
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G-5
Technical Information
APPLICATIONSDrilling
Troubleshooting
•speeds&feeds
•cuttingfluid•others
•Maintainconstantfeedrate•Reducethecuttingspeed•Reducethefeedrate•Increasecoolantflow•Useamachinewithsufficienthorsepower•Tightenworkpiececlamping
•tool•speeds&feeds
•others
•Reducedrilloverhang•Maintainconstantfeedrate•Reducethefeedratewhenstartingdrill•Useamachinewithsufficienthorsepower•Tightenworkpiececlamping
•tool•speeds&feeds
•others
•Reducedrilloverhang•Maintainconstantfeedrate•Reducethecuttingspeed•Useamachinewithsufficienthorsepower•Tightenworkpiececlamping
•tool•speeds&feeds
•cuttingfluid•others
•Reducedrilloverhang•Maintainconstantfeedrate•Changethefeedrate•Increasecoolantflow•Useamachinewithsufficienthorsepower•Tightenworkpiececlamping
•tool
•speeds&feeds
•Lessleadangle•Increasehone•Maintainconstantfeedrate•Increasethefeedrate
•speeds&feeds•cuttingfluid•others
•Maintainconstantfeedrate•Maintainconstantcoolantflow•Useamachinewithsufficienthorsepower
Drill Breakage
Center Point Breakage
Peripheral Cutting EdgeBreakage
Chipping
Long Stringy Chips
Chip Form Varies
PROBLEM CAUSE RECOMMENDED ACTION
®
Technical Information
G-6
Technical Information
APPLICATIONSDrilling
Troubleshooting
•tool
•speeds&feeds
•others
•Reducedrilloverhang•Increaseleadangle•Increasethecuttingspeed•Reducethefeedrate•Useamachinewithsufficienthorsepower•Tightenworkpiececlamping
•speeds&feeds
•others
•Maintainconstantfeedrate•Increasethecuttingspeed•Reducethefeedrate•Uselowfeedratewhenstartingdrill•Useamachinewithsufficienthorsepower•Tightenworkpiececlamping
•tool•speeds&feeds
•others
•Reducedrilloverhang•Reducethecuttingspeed•Increasethefeedrate•Useamachinewithsufficienthorsepower•Tightenworkpiececlamping
•tool
•speeds&feeds•others
•Uselighthone•Reducedrilloverhang•Maintainconstantfeedrate•Useamachinewithsufficienthorsepower•Tightenworkpiececlamping
Over Size or Out-of-Round
Poor Surface Finish
Galling on Drill Body
Vibration
PROBLEM CAUSE RECOMMENDED ACTION
AISI SAE
AISI201
AISI202
AISI301
AISI302
AISI302B
AISI303
AISI303Se
AISI304
AISI304L
AISI304N
AISI305
AISI308
AISI309S
AISI310S
AISI316
AISI316L
AISI316N
AISI317
AISI317L
AISI321
AISI347
AISI384
ASTMXM7
ASTMXM15
AISI405
AISI429
AISI430
AISI430F
AISI434
ASTMXM27
AISI403
AISI410
AISI410S
AISI416
AISI420
AISI420F
AISI431
AISI440A
AISI440B
AISI440C
ASTM440F
ASTM631
AISI632
AISI SAE
1010
1015
1020
1025
1030
1035
1040
1045
1050
1055
1060
1010
1015
1020
8620
8640
4320
4340
5130
5135
5140
5147
4130
4135
4140
4145
1520
1536
1541
1522H
1541H
5120H
5130H
5135H
5140H
4135H
4140H
4145H
8620H
4320H
AISI ASTM
W1-13
W1-111/2
W1-10
W1-9
W1-8
W1-7
T1
T4
T15
M2
M3-1
M3-2
M4
M36
M7
M42
F2
L6
W2-91/2
W2-81/2
D3
D2
A2
H11
H13
P20
®
Tech
nica
l Inf
orm
atio
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G-7
Technical Information
TYPE• Stainless Steel
JIS
SUS201
SUS202
SUS301
SUS302
SUS302B
SUS303
SUS303Se
SUS304
SUS304L
SUS304N1
SUS305
SUS308
SUS309S
SUS310S
SUS316
SUS316L
SUS316N
SUS317
SUS317L
SUS321
SUS347
SUS384
SUSXM7
SUSXM15J1
SUS405
SUS429
SUS430
SUS430F
SUS434
SUSXM27
SUS403
SUS410
SUS410S
SUS416
SUS420
SUS420F
SUS431
SUS440A
SUS440B
SUS440C
SUS440F
SUS631
SUS632
DIN
DINX10CrNiS189
DINX5CrNi1810DINX2
CrNi1911
DINX2CrNi1812
DINX2CrNiMo17122
DINX2CrNiMo17132
DINX2CrNiMo18164
DINX6CrNiTi1810DINX6
CrNiNb1810
DINX6CrAl13
DINX6Cr17
DINX12CrMoS17DINX6CrNb17
DINX10Cr13DINX6Cr13
DINX20Cr13
DINX20CrNi172
DINX7CrNiA1177
Aus
teni
ticFe
rriti
cM
arte
nsiti
c
JIS
S10C
S15C
S20C
S25C
S30C
S35C
S40C
S45C
S50C
S55C
S58C
S09CK
S15CK
S20CK
SNCM220
SNCM240
SNCM420
SNCM439
SCr430
SCr435
SCr440
SCr445
SCM430
SCM435
SCM440
SCM445
SMn420
SMn433
SMn438
SMnC420
SMnC443
SMn420H
SMn438H
SCr420H
SCr430H
SCr435H
SCr440H
SCM435H
SCM440H
SCM445H
SNCM220H
SNCM420H
DIN
C10
C15
C22
C25
C30
C35
C40
C45
C50
C55
C60
CK10
CK15
CK22
34Cr4
42Cr4
34CrMo4
42CrMo4
34Cr4
37Cr4
41Cr4
34CrMo4
42CrMo4
TYPE
Car
bon
Stee
lNi
ckel
Chr
omiu
mM
olyb
denu
mSt
eel
Chr
omiu
mSt
eel
Man
gane
se S
teel
and
Man
gane
seC
hrom
ium
Ste
el
Stru
ctur
al S
teel
with
Que
nchi
ngPr
oper
ty G
uara
ntee
d(H
Ste
el)
• Carbon Steel & Alloy SteelJIS
SK1
SK2
SK2
SK4
SK5
SK6
SK7
SKH2
SKH3
SKH10
SKH51
SKH52
SKH53
SKH54
SKH56
SKH58
SKH59
SKS11
SKS51
SKS43
SKS44
SKD1
SKD11
SKD12
SKD6
SKD61
DIN
C105W1
C80W1
C80W1
C70W2
S6-5-2
S6-5-3
S2-10-1-8
105WCr6
X210Cr12
38CrMoV5
40CrMoV5
40CrMnMo7
TYPE
Car
bon
Tool
Ste
el
• Tool Steel
Hig
h Sp
eed
Stee
lA
lloy
Tool
Ste
el
Material Cross Reference
Chro
miu
mM
olyb
denu
mSt
eel
AISI ASTM
A48-20B
A48-25B
A48-30B
A48-35B
A48-40B
A48-50B
60-40-18
65-45-12
80-55-06
100-70-03
AISI ASTM
AISI309
AISI310
AISI330
ASTM660
ASTM661
AISI409
AISI446
ASTM616
®
Technical Information
G-8
Technical Information
DIN
GG-10
GG-15
GG-20
GG-25
GG-30
GG-35
GGG-40
GGG-50
GGG-60
GGG-70
TYPE
Gra
y C
ast I
ron
• Cast Iron
Duc
tile
Cas
t Iro
n
DIN
INCrNi252
INX6CrTi1
TYPE• Heat Resistant Steel
Material Cross Reference
Aus
teni
ticFe
rriti
cM
arte
nsiti
c
JIS
SUH309
SUH310
SUH330
SUH0
SUH61
SUH409
SUH446
SUH1
SUH3
SUH4
SUH11
SUH600
SUH616
JIS
FC100
FC150
FC200
FC250
FC300
FC350
FCD400
FCD500
FCD600
FCD700
0.050.080.100.200.300.130.050.080.100.300.400.040.08
0.450.180.080.17
0.080.100.400.030.030.040.040.100.100.050.050.040.050.080.050.050.080.150.100.150.040.050.120.050.130.050.120.04
0.050.100.040.060.130.120.180.150.150.05
0.25
0.150.030.060.450.650.250.250.12
0.99
0.77
0.350.90
0.700.600.800.40
1.00
0.55
0.700.900.200.500.350.350.300.700.400.300.300.500.40
1.001.00
1.00
0.200.220.600.500.250.700.400.30
1.000.25
0.150.150.150.150.30
0.06
0.551.000.102.253.753.003.253.40
26.0033.0025.00
0.354.5026.0030.0020.009.0020.0026.0025.00
20.002.0025.500.45
0.2512.00
6.509.0032.5032.0053.0054.0058.0047.0073.0076.0058.0061.0060.0054.0062.0036.0045.0076.0043.0076.0076.0046.0043.0072.0052.00
57.0048.0073.0054.6075.0066.0066.0065.0065.0061.00
98.60
94.0038.0056.4082.8080.0088.2590.5095.50
1.304.006.001.002.752.853.00
3.001.404.001.50
4.00
1.250.65
0.80
1.30
10.0010.004.504.00
5.3028.0016.005.509.009.00
5.70
3.00
4.503.00
6.009.00
3.305.50
9.00
3.205.25
-
1.100.404.00
0.50
4.00
0.40
0.451.20
0.30
0.90
2.255.20
0.95
2.00
4.00
0.200.25
0.200.40
0.200.35
0.25
0.37
1.600.801.203.000.901.001.404.30
2.00
0.061.003.200.206.000.50
2.001.300.704.506.00
2.752.802.800.20
4.500.204.25
54.0040.005.0097.7085.0075.8054.0053.0030.0066.0047.0054.8054.00
26.5081.8054.1058.90
79.6063.0091.9077.6074.4046.0044.502.002.002.002.007.000.500.504.605.505.5010.0018.5024.007.0035.302.400.500.8013.001.0018.50
18.507.00
1.351.351.001.003.00
0.10
0.156.170.502.504.253.501.001.00
®
Tech
nica
l Inf
orm
atio
n
G-9
Technical InformationChemical Components
A-286M-308(J-1300)16-25-6(Timkin)Chromalloy(Unitemp14CMV)LapelloyAm-355DiscaloyTinadurN-155(Multimet)19-9DLS-588W545Unitemp212
S-590Unitemp1415NW(GreekAscoloy)V-57H46
H53EMEUnimach#1Almar362Custom455Incoloy800Incoloy801Rene41M-452(J-1500)WaspaloyUdimet500InconelXNimonic80ANimonic90DCMHastelloyBHastelloyCHastelloyR-235HastelloyXHastelloyWInconel(600)Incoloy901Nimonic75Nimonic80AInconel700K-42-BInconel713CInconel718
Allvac620Pyromet860InconelX-750AstroloyInconel713Monel713y400MonelAlloyR405MonelAlloyK-500MonelAlloyK-500(aged)Inconel625
PermanickelAlloy300
DuranickelAlloy301Refractaloy26Udimet700Colmonoy4Colmonoy5Colmonoy20Colmonoy21Colmonoy22
1.40
1.40
0.750.60
1.501.001.501.50
1.50
0.25
0.50
0.300.500.750.750.301.000.700.700.700.700.50
1.001.00
1.00
0.400.480.400.700.080.700.150.20
1.000.70
0.900.900.600.600.15
0.10
0.250.801.00
15.0014.0016.001.0011.5015.5013.0015.0021.0019.0018.0013.0016.00
20.0013.0014.7512.00
10.5019.005.0014.5011.7521.0020.5019.0019.0019.0019.0015.0020.0020.0014.301.0015.5015.5022.0022.0015.5012.8020.0020.0015.0018.0013.0019.00
19.0016.0015.5015.0012.00
22.00
18.0015.0010.0011.505.005.00
-
19.50
20.00
7.00
11.0010.0014.0018.00
16.00
2.502.502.501.50
29.0022.00
12.004.00
18.00
30.0018.45
-6.50
2.401.304.00
4.003.00
0.803.20
3.75
0.60
1.000.60
2.002.00
1.801.751.000.30
2.804.00
3.00
0.801.200.371.1232.002.502.503.002.502.302.303.40
2.50
2.500.402.302.202.500.600.90
3.003.002.503.500.60
0.500.500.500.20
0.50
0.502.603.50
0.003
0.080
0.008
0.0050.0050.0050.005
0.080
0.0100.010
0.050
0.0302.0002.5001.0001.2501.350
0.300.250.150.120.250.11
1.000.13
0.060.05
0.300.350.050.550.150.50
2.250.300.15
0.060.05
0.400.35
0.30
0.050.05
0.055.02
0.50
31.5031.5029.5029.503.650.100.020.350.05
VZRNVVN
TaN
BRZR
VVNVNV
CuCuCu
ZRZR
VV
V
CuCu
CuTa
Cu
CuCuCuCuTaCuCuMgCu
MATERIAL C Mn Si Cr Ni Co Mo W Cb Ti Al B Fe OTHER
Hea
t-Res
ista
nt A
lloys
Fe B
ase
Ni B
ase
0.200.200.380.120.250.400.400.400.45
1.000.020.02
2.20
0.001
0.01
0.15
0.120.15
0.701.000.600.600.600.600.50
1.25
0.15
1.00
30.0027.0020.0010.003.0010.0016.002.001.00
10.0022.50
2.50
7.502.50
4.00
5.00
6.006.00
2.004.00
1.00
10.005.00
5.00
99.8099.4098.4069.80
4.00
2.00
80.0079.0085.0080.0058.50
87.5099.00
0.22
5.00
6.00
7.00
8.00
6.004.00
7.001.00
6.00
8.00
3.00
3.001.001.001.001.001.001.70
1.000.30
3.00
2.00
5.00
®
Technical Information
G-10
Technical Information
J-1570J-1650S-816L-605(HS-25)HS-21(Vitallium)HS-31(X-40)HS-30(422-19)HS-27WI52
Wallex#6(Colmonoy)Jetalloy209Nivco
StelliteJCommerciallyPure(annealed)110-170BHN140-200BHN200-275BHN
ALPHATi-5AL-2.5Sn(annealed)
Ti-6AL-1V-4Zr(annealed)
Ti-7AL-2Cb-1Ta(annealed)
Ti-8AL-1Mo-1V(heattreated)290-335-BHN
Alpha-bataTi-6AL-4V(annealed)Ti-4AL-4Mn(annealed)Ti-2Fe-1Cr-2Mo(annealed)Ti-7AL-4Mo(annealed)Ti-1Al-8V-5Fe(annealed)
Alpha-beteTi-6AL-6V-25M-1(Fe,Cu)(Annealed)
Ti-8AL-1Mo-1v
BetaTi-13V-11Cr-3AL(solutiontreated)COLUMBIUM(Cb)D-31F-48Cb-74Cb-129Cb-132M
Cb-7521%Zr
TUNGSTEN(W)W-ForgedRolledW-Sintered(28-35Rc)W-10W-2
TANTALUM(Ta)Ta-10WT-111
T-222
Ta
MOLYBDENUM(Mo)MolybdenumTZMTZC70Mo-30W
Chemical Components
5.00
1.501.500.600.600.60
5.00
0.35
1.00
4.00
20.0019.0020.0020.0027.0025.0024.0023.0021.00
29.0020.000.50
31.00
2.00
11.00
39.0036.0043.0051.0062.0055.0051.0067.0061.70
64.3050.0073.50
43.30
6.5012.004.0015.00
8.00
11.00
4.5015.00
16.00
15.0010.0010.0015.0015.00
10.00
99.9099.9090.0097.50
10.008.00
10.00
30.00
0.020 2.00
0.040.04
1.100.01
2.50
4.001.002.001.001.001.00
4.00
8.00
1.00
6.00
13.00
1.005.0010.002.001.502.501.00
2.50
90.0090.002.0087.502.5099.80
0.080.15
Ta
PS
ZRS
Sn
ZrVCbTaMoV
V
V
FeCuV
V
ZrZrHfTaZrZrZr
Cu
TaTaHfTaHf
ZrZr
MATERIAL C Mn Si Cr Ni Co Mo W Cb Ti Al B Fe OTHER
Oth
er C
ut R
esis
tant
Mat
eria
ls
4.103.80
2.001.80
99.5099.2099.00
92.50
89.00
90.00
90.00
90.0092.0094.0089.0086.00
87.00
90.00
73.00
10.00
0.501.25
Tita
nium
Allo
ysC
o B
ase
®
Tech
nica
l Inf
orm
atio
n
G-11
Technical Information
Conversion Table Reference - Hardness Scales
Brinell,10mmBall,Load3000kg,
StandardBall
HB
Vickers
HV
BScale,Load100kg,Diameter
1/16in.SteelBall
HRB
CScale,Load150kg,
120°DiamondCone
HRC
Shore
HS
Rockwell
940920900880860
840820800-
780760
740737720700697
690680670667
677640
640615
607591
579569553547
539530528
516508508
495491491
474472472
-----
------
-----
----
--
--
--
----
---
---
---
---
68.067.567.066.465.9
65.364.764.0-
63.362.5
61.861.761.060.160.0
59.759.258.858.7
59.157.3
57.356.0
55.654.7
54.053.552.552.1
51.651.151.0
50.349.649.6
48.848.548.5
47.247.147.1
9796959392
919088-8786
-8483-81
-80-79
-77
-75
-73
-71-70
--68
--66
--65
--63
Brinell,10mmBall,Load3000kg,
StandardBall
HB
Vickers
HV
BScale,Load100kg,Diameter
1/16in.SteelBall
HRB
CScale,Load150kg,
120°DiamondCone
HRC
Shore
HS
Rockwell
455440425410396
383372360350339
328319309301292
284276269261253
247241234228222
218212207202196
192188182178175
171163156150143
137132127122117
-----
-110.0109.0108.5108.0
107.5107.0106.0105.5104.5
104.0103.0102.0101.0100.0
99.098.297.396.495.5
94.693.892.891.990.7
90.089.087.886.886.0
85.082.980.878.776.4
74.072.069.867.665.7
45.744.543.141.840.4
39.137.936.635.534.3
33.132.130.929.928.8
27.626.625.424.222.8
21.720.518.817.516.0
15.213.812.711.510.0
9.08.06.45.44.4
3.30.9---
-----
6159585654
5251504847
464543-41
4039383736
3534-33-
32313029-
2827-26-
25-232221
-20191815
Note: FiguresinparenthesesunderBrinellindicatevaluesusingtungstencarbideball.
---
(767)(757)
(745)(733)(722)(712)(710)(698)
(684)(682)(670)(656)(653)
(647)(638)(630)(627)
-(601)
-(578)
-(555)
-(534)-
(514)
495--
477--
461--
444--
429415401388375
363352341331321
311302293285277
269262255248241
235229223217212
207201197192187
183179174170167
163156149143137
131126121116111
®
Technical Information
G-12
SAFETY PAMPHLET1. In using tungsten carbide tools.Asproductliability(PLLaw)hasbeenenforcedon1stJuly1995,DijetIndustrialCo.,Ltd.(hereafterDijet)startedtoappendawarningorcautionlabelonthepackagematerialsforpertinentproducts.
However,onthetoolbodies,nowarningorcautionlabelisattached,andtherefore,youshouldreadthissafetypamphletbeforeyouuseanykindofDijetproductsorothertoolsmadeofourhighhardmaterials.
Youarealsorequestedtomakewellknownthecontentsofthispamphlettoeveryworkerinyourplantasapartofyourplantsafetyeducationprogram.
2. Basic features of high hard tools materials.Thehighhardtoolsmaterialisageneraltermforthesinteredmaterialoftungstencarbidealloy,thechiefingredientofwhichistungstencarbide(WC),cermetwhosechiefingredientsaretitaniumnitride,carbide,cubicboronnitride(CBN)and/orsintereddiamond.Thesematerialsaresometimescalledjust“hardmetal”.
2-1. Physical properties of hard metal. Appearance :Itdiffersaccordingtothematerials/ Exam:gray,darkgray,black,gold,etc. Smell :Odorless Hardness :Carbide&Cermet-HV500 Ceramics-HV1.000 CBN-HV2,500 Sintereddiamond-HV8,000 Density :Carbide-9-15 Cermet-6-9 Ceramics&CBN-3-5
2-2. Ingredients Carbide,Nitride,Carbo-nitrideandOxideofW,Ti,Al,TaorBandinaddition,insomeof them,metalingredientslikeCo,Ni,CrorMoetc.arecontained.
3. Precautions for handling hard metal tool materials.•Hardmetalshavethefeatureofhighhardnessbutarealsobrittle.Therefore,theywillcrackbystrongimpactorclampingtoofast.•Hardmetalsareveryheavy.Incaseoflargesizedtoolsorbigquantities,theyneedtobehandledasweightcargo.•Theheatexpansionrateofhardmetalisdifferentfromthatofsteelmaterials.Therefore,shrinkfittedorforcefittedtoolscanbreakiftheyareinextremelyhigh(orlow)temperaturethanthedesignedvalue.
4. Precautions for processing of hard metal.•Whencooledbygrindingsolutionorwaterthestrengthofthematerialcandeteriorate.Specialattentionshouldbemadeforstorageconditionofthesematerials.Accordingtothesurfacecondition,thestrengthofmaterialswillbegreatlylowered.Useadiamondwheelforfinishingofsurfaceroughness.•Dustwillbegeneratedingrindingoperation.Chronicinhalationmaycause“hardmetallung:andisdangeroustoyourhealth.Provideexhaustventilationandwearappropriateprotectiveequipmentlikedustmask,etc.Whenskincontactoreyecontactoccurs,washthoroughlywithwater.•Ingrindingofhardmetalsorbrazedtools,heavymetalingredientwillremaininthewastefluid.Wastefluidmustbecompletelydisposedofinasafeway.•Afterre-grindingofbrazedtools,confirmthatcracksonthesurfaceoftoolsarecompletelyeliminated.•Inmarkingonhardmetalmaterialsoffinishedgoodswithlaserorelectricpens,minutecracksbaybegeneratedonthesurfaces.•Avoidmarkingonthepositionwherestresswillbeimposed.Inelectricdischargingprocessonhardmetal,residuecrackswillremainonthesurfacescausingloweringofstrength.Thesecracksmustbecompletelygroundoff.
®
Tech
nica
l Inf
orm
atio
n
G-13
Instructions For Using Cutting Tools
Directcontacttothesharpcuttingedgemaycauseinjury.
Misuseormismatchofworkingconditionsmaycausetoolbreakageordispersionofbrokerpieces.
Excessimpactorheavywearwillincreasecuttingresistanceandmaycausetoolbreakageanddispersionofbrokenpieces.
Dispersionofheatedorprolongedchipsmaycauseinjuryorburn.
Duringcuttingoperation,cuttingtoolsgetveryhot.Directcontacttotoolsimmediatelyafteroperationmaycauseburn.
Sparks,generationofheatorchipsinhightemperatureduringoperationmaycausefire.
Lackofdynamicbalanceinhighspeedrotationmaycauserunoutandthetoolmaybreakbyvibration.
Directcontacttotheburrsontheworkpartmaycauseinjury.
Wheninsertsorpartsarenotclampedproperly,fallingoffordispersionmayoccurandcauseinjury.
Whenclampedtootightbysupplementarytoolslikepipeetc.,insertsorbodymaybebrokenandunusable.
Whenindexabletoolsareusedinhigh-speedrotation,insertorpartsmayburstoutofthebodyduetoantifugalforce.
Sincemillingcuttershavesharpedges,directcontactwithbarehandsmaycauseinjury.
Ifcutterlacksdynamicbalanceorrotateseccentrically,toolbreakageordispersionofbrokenpiecesmayoccurbyrunoutorvibration.
Whendrillingthroughholeonworkpiece,adiscofworkmaterialmayflyoutendofhole.Itisverydangeroussincethedischassharpedges.
Microdrillshavesharppoints,directcontactwithfingersisdangerous.Ifbroken,smallpiecesmayremaininthewoundanddispersearoundthebody.
Dispersionofbrokentipsbytoolbreakageorfallingoftoolmaycauseinjury.
Whenbrazingiscarriedouttimeandagain,thestrengthofcarbidetipisdeterioratedandbecomeseasilybrokenduringoperation.
Itisdangeroustousetoolsotherthanthefixedapplication.Itmaycausedamageoftoolandmachine.
ITEM HAZARD COUNTERMEASUREWearprotectivegloveswhentakingoutofboxormountingtothemachine.
Providesafetycovers,wearsafetyglassesand/orprotectivegloves.Readinstructionmanualbeforeusing.Refertotherecommendedconditionsincatalog.
Changetoolsalittleearly.Providesafetycovers,wearsafetyglassesandprotectivegloves.
Providesafetycovers,wearsafetyglassesand/orprotectivegloves.Getridofchipssafely.
Wearprotectiveequipmentlikeprotectivegloves.
Avoidoperationwhenignitionorexplosionisexpected.Wheninsolublecoolantisused,enoughfirefightingmeasuremustbetaken.
Providetestrunandconfirmifvibrationorchatteringisobserved.
Donotcontactwithbarehand.Wearprotectivegloves.
Cleanuptheinsertpocketorfasteningpartsbeforereloading.Confirmiftheinsertsorpartsarecorrectlyclampedbythesuppliedwrench.
Besuretousesuppliedwrench.
Usewithintherecommendedcuttingconditions.Refertotheinstructionmanualoncatalogs.
Wearprotectivegloves.
Usethecutterwithintherangeofrecommendedworkingconditions.Rotatingportionanddynamicbalancingshouldbeperiodicallycheckedtopreventeccentricrotationorrunoutduetowearofbearingportion.
Providesafetycovers,wearsafetyglassesand/orprotectivegloves.Alsoprovideprotectivecoversarounddrillholding.portion.
Handlecarefullywithprotectiveglovesandprotectiveglasses.
Confirmiftipsarefirmlybrazed.Avoidusinginthiscondition,whichrequiresgenerationofhighcuttingtemperature.
Carbidetipwhichisbrazedseveraltimesshouldnotbeused,itsstrengthhasdeteriorated.
Usethetoolasprescribedintheinstructionmanual.
GeneralCutting Tools
IndexableCutting Tools
MillingCutters
and OtherRotating
Tools
Drill
BrazedTools
Others
®
Technical Information
G-14
Parts
DRAWINGDIMENSIONS
BA C DWrench
Adjustable ScrewsCATALOGNUMBER E a°
4.87.85.6
9.0
No.10-32UNFM5x0.5M5x0.5
M5x0.5
12.713.014.5
13.0
4.85.06.5
5.0
---
-
---
-
AD-1845AD-2080AD-2080
AD-1845
A B
CD
A B
CD
DRAWINGDIMENSIONS
BA C DWrench
Clamp ScrewsCATALOGNUMBER E
9.0
2.73.53.03.45.55.55.05.05.06.66.42.54.34.34.35.26.05.35.36.86.86.87.07.07.23.63.64.04.04.05.35.35.35.35.36.86.86.8
M3.5x0.6
M1.8x0.35M2.5x0.45M2.5x0.45M2.5x0.45M3.5x0.6M3.5x0.6M4x0.7M4x0.7M4x0.7
M4.5x0.75M5x0.8
M1.8x0.35M3x0.5M3x0.5M3x0.5M4x0.7M4x0.7M4x0.7M4x0.7
M4.5x0.75M4.5x0.75M4.5x0.75M5x0.8M5x0.8M5x0.8
M2.5x0.45M2.5x0.45M3x0.5M3x0.5M3x0.5M4x0.7M4x0.7M4x0.7M4x0.7M4x0.7M5x0.8M5x0.8M5x0.8
6.3
3.75.04.24.77.09.56.07.08.010.011.03.86.57.57.67.58.58.610.010.012.515.59.511.512.55.56.04.56.07.55.96.68.010.012.07.58.210.0
2.3
1.82.42.52.53.53.53.63.63.64.04.52.03.22.83.23.53.63.53.74.75.25.24.94.96.02.02.02.02.02.02.72.72.72.72.73.43.43.4
-
--------------------------------------
-
5555434355554343435743555555555555555555555555555560605555555555555555555555
T-15
T-6T-8T-7T-7T-15T-15T-15T-15T-15T-20T-20T-6T-10T-10T-10T-15T-15T-15T-15T-20T-20T-20T-20T-20T-25T-8T-8T-8T-8T-8T-15T-15T-15T-15T-15T-25T-25T-25
2.1
0.250.90.90.92.12.13.63.63.65.05.50.41.81.41.83.63.63.63.66.06.06.06.16.16.10.90.91.41.41.43.13.13.13.13.15.55.55.5
A B
CD
A B
CD
aº
A B
CD
aº
A B
CD
aº
a°Torque
Nm
1.55
.18
.66
.66
.661.551.552.662.662.663.694.06-
1.331.031.332.662.662.66-
4.434.43-
4.504.504.50.66.661.031.031.032.292.292.292.292.294.064.064.06
Torquelbs./ft
CB3540
CSW-1838CSW-206CSW-2542CSW-2547CSW-3570CSW-3595CSW-406HCSW-407CSW-408HCSW-4510CSW-510
DSW-1838HDSW-306HDSW-307DSW-307HDSW-4075DSW-408DSW-4085DSW-410HDSW-4510HDSW-4512HDSW-4515HDSW-509DSW-511HDSW-512VESW-205ESW-206ESW-304ESW-306ESW-307ESW-405ESW-406ESW-408ESW-410ESW-412ESW-507ESW-508ESW-510
ASW-113ADS-513ADS-514
ASW-513
®
Tech
nica
l Inf
orm
atio
n
G-15
Parts
DRAWINGDIMENSIONS
BA C DWrench
Clamp ScrewsCATALOGNUMBER E a°
6.6
6.6
2.53.03.84.75.86.88.511.0
10.0
3.13.65.35.57.08.5
M5x0.8
M5x0.8
M2x0.25M2.5x0.35M3x0.35M3.5x0.6M4x0.7M5x0.8M6x1.0M8x1.25
M6x1.0
M2.2x0.45M2.5x0.45M3.5x0.6M4x0.7M5x0.8M6x1.0
10.9
9.5
5.06.68.19.613.516.420.025.0
15.0
5.05.611.58.011.012.0
5.5
5.5
1.31.52.02.33.33.24.35.5
7.3
2.32.74.53.35.04.8
-
-
--------
-
------
60
60
4040404040404040
60
606060606060
T-20
T-20
T-06T-07T-08T-10T-15T-20T-30T-40
T-30
T-07T-08T-15T-15T-20T-25
5.5
5.5
0.50.91.22.03.04.05.06.0
7.5
0.60.92.13.15.57.5
A B
CD
aº
A B
CD
aº
aº A B
DC
aº A B
CD
DRAWINGDIMENSIONS
B
HCS4-10
HCS5-10
A C DWrench
Hexagon Socket Head Cap ScrewsCATALOGNUMBER E F
Torque
7.0
8.5
M4x0.7
M5x0.8
14.0
15.0
4.0
5.0
3.0
4.0
-
-
-
-
-
-
A B
CD
E
DRAWINGDIMENSIONS
BA C DWrench
Wedge ScrewsCATALOGNUMBER E F
4.6
4.64.64.65.54.86.0
M6x1.0
M6x1.0M6x1.0M6x1.0M7x0.75M6x0.75M8x1.0
22.0
16.014.513.019.022.019.0
TorqueNm
8.5
6.56.55.07.58.07.0
8.5
6.55.05.08.08.08.0
3.0
3.03.03.0---
-
---
T-25T-15T-27
6.0
6.06.06.07.06.08.0
F
A
CD E F
B B
F
A
B BED
CA
B B
CD E
4.43
4.434.434.435.16-
5.90
Torquelbs./ft
LS-1
LS-101LS-106LS-107LS-109LS-110LS-180
4.06
4.06
.37
.66
.891.482.212.953.694.43
5.53
.44
.66-
2.294.065.53
TorqueNm
Torquelbs./ft
FS1030
FS1030S
FSW-2005HFSW-2506HFSW-3007HFSW-3509FSW-4013FSW-5016FSW-6020FSW-8025
HSW-614H
TSW-2250TSW-2556HTSW-3512HTSW-408TSW-511TSW-612
DRAWINGDIMENSIONS
B
SSW-535
SSW-745
A C DWrench
Shim ScrewsCATALOGNUMBER E a°
6.3
8.4
M5x0.5
M7x0.5
7.0
8.0
3.1
2.9
3.5
4.5
-
-
6.5
8.0
-
-
TorqueNm
Torquelbs./ft
-
-
A
E
B
CD
®
Technical Information
G-16
Parts
DRAWINGDIMENSIONS
BLW-025LW-030LW-035LW-040LW-045LW-050
A-030
A-07SDA-08SDA-10SDA-20SDA-25SDA-06A-07A-08
A-10
A-15
A-20W
A-15TA-20A-20LA-25A-27A-30A-40
AD-1845
AD-2080
A C DWrench Size
WrenchesCATALOGNUMBER E
59.567.071.575.080.580.0
-
4.04.04.05.05.01.72.02.3
3.0
3.5
4.0
4.04.05.54.55.56.07.0
1.8
2.0
18.020.022.525.02728.0
60.0
60.070.070.090.0100.034.534.539.0
40.0
45.0
45.0
100.0100.0200.0100.0100.0100.0100.0
45.0
45.0
------
80.0
80.080.095.0105.0105.015.015.019.0
40.0
40.0
40.0
80.0100.0100.0100.0100.0100.0100.0
-
35.0
------
28.0
-----
15.015.919.0
20.0
20.0
20.0
26.032.032.032.032.032.032.0
-
-
2.53.03.54.04.55.0
3.0
--------
-
-
-
-------
-
-
------
-
T-7T-8T-10T-20T-25T-6T-7T-8
T-10
T-15
T-20
T-15T-20T-20T-25T-27T-30T-40
-
-
A
EB
BD
CE
C B
A
D B
AC
D B
CA
BD
AC
B
A
B
A
C
DRAWINGDIMENSIONS
B
SLS-3
A C DWrench
Clamp ScrewsCATALOGNUMBER E F
TorqueNm
6.0 M8x1.0 20.0 8.0 8.0 4.0 - 8.0
A
B B
FED
C
5.90
Torquelbs./ft
DRAWINGDIMENSIONS
B
LS-113
A C DWrench
Rest Button ScrewsCATALOGNUMBER E F
Torque
3.7 No.10-32UNF 10.2 4.5 4.1 2.4 - -
A
B B
F DC
E
®
Tech
nica
l Inf
orm
atio
n
G-17
Parts
DRAWINGDIMENSIONS
B
RSW-05008
A C DWrench
Hexagon Socket Set ScrewCATALOGNUMBER E F
Torque
- M5x0.8 8.0 - - - T-10 -
B
C
DRAWINGDIMENSIONS
B
DCM-1
DCM-5
DCM-17
DCM-18
A C D
Clamp SetsCATALOGNUMBER E
WrenchF G
M5x0.8
M6x1.0
M4.5x0.75
M3.5x0.6
13.8
17.0
11.7
10.0
13.8
16.5
18.0
13.0
6.8
8.9
10.5
7.6
2.0
2.0
5.0
3.0
8.5
10.0
10.0
7.2
2.5
3.0
-
-
-
-
T-20
T-15
A
C
F
G
DE
B
A
C
F
DE
B
DRAWINGDIMENSIONS
B
DCM-2
A C D
ClampCATALOGNUMBER E F
M8x1.0 10.0 19.0 11.0 6.0 13.5C
F
A
E D
B
DRAWINGDIMENSIONS
B
CW-11
A C D
Clamp WasherCATALOGNUMBER a° β°
8.0 5.0 11.0 4.0 55 12
βº
Aaº
D
B C
DRAWINGDIMENSIONS
B
LSM-512
A C DWrench
Adjustable ScrewCATALOGNUMBER E F
Torque
- M5x1.0 12.6 1.0 3.0 2.5 - -
B
F CD
E